2ND BATTALION 94TH ARTILLERY
2/94th Battalion Update Number 40
Battalion monument under construction
Pictures and descriptions below
I did want to mention I had a nice phone call from Colonel Krueger 69-70 who resides not too far from me and we will be getting together for dinner after my return from Sill. Colonel Krueger will not be able to join us.
Special thanks to Gary and Sharon Goedecke without whose tireless efforts and personal dedication to the Battalion monument project at Fort Sill.
Captain Gary Goedecke and his wife Sharon have been getting the monument site ready.
Slab & foundation hole with form tube imbedded are ready for the reinforcing steel - No. 4 rebar (1/2" diameter).
A jig was built for tying No. 3 rebar pieces into the square shape that will align and hold the vertical rebars up from the 48" deep foundation hole, through the slab and the pedestal, and on up into the projo. Tying pliers and rebar wire in its reel are the tools used, along with lot of clamps
The vertical cage of No. 4 rebar is nearly finished. Lots of clamps really help hold the parts together while everything is being tied. On the left is the rebar cutter/bending tool, it is hefty and handy! The purpose of the jig-built square frames is to hold the rebars in the designed alignment.
The base of the scaled up 175mm projo is 11" in diameter and the four No. 4 rebars had to pass through that diameter and leave 1-1/2" margin for concrete to cover the rebar. So the rebar cage is 8" diameter from corner to corner. I drew the design for the jig in an electronic drafting program called AutoCAD, and also checked clearances with the projo base for minimum concrete coverage. ACad is a design and time saver! One can draw in full scale and print patterns in full scale to build from.
The vertical rebar is ready for insertion into the 48" deep foundation hole. Notice that the bottom of the cage is standing on two plastic devices called "castle chairs" that are wired onto the bottom frame. They are used to space the rebar above the base in the hole so that concrete can properly fill in around them, and the rebar, to isolate and to protect the rebar from rusting and corroding away. Minimum concrete coverage for rebar is 1-1/2" from any surface, ground, water, or weather.
The vertical rebar cage is fully into the foundation hole and the first horizontal rebars are ready to be wired to the vertical rebar. The levels and tape measures allow quick reference while building the reinforcing grid that the verticals remains plumb and centered in the 12"x 48" deep foundation hole. The castle chairs are supporting the horizontal rebar above the slab base.
Checking everything! Slab reinforcing is nearly completed. The vertical rebars will have additional bent rebar angles tied from the verticals to the horizontal grid at each corner of the vertical rebar cage. The angles will transfer any vertical side loads on the projo into the horizontal slab, as a backup to the 48" deep foundation that will resist overturning of the projo. This set up, when finished, should withstand and 8" precision-fire mission!!! The tall steel stakes are temporary and will hold the rebar grid in alignment while concrete is poured into the foundation hole.
Almost ready to pour! The 16" diameter x 10" high pedestal form is in place to verify clearances. It will be used as a "slip form". After the foundation is filled, and as the slab is being poured, the pedestal form will be partially filled and carefully "slipped" vertically, while maintaining alignment, to its designed height of 10" above the 5" slab.
The rebar angles at the corners of the vertical cage are visible tied above the tube form and are tied to the horizontals where they emerge from under the form. (Four more angles in the "Y" direction were added after this picture was taken.)
The verticals for the projo, in phase two of the project, will be splice (lapped) onto the four vertical bars emerging from the pedestal top. The rule for splicing is that 24 bar diameters are the minimum splice length. With No. 4 rebar that means a lap splice of 12". Such a configuration is then considered "continuous" reinforcing.
Looking down into the foundation hole. The two castle chairs can be discerned at the bottom doing their job! The top ends of the angled rebars, tying the verticals to the horizontals, are visible.
4 May 2006
Shots of projo without the fuse in preparation for spraying tooling gelcoat to create the pattern, or plug, from which the two mold halves will be formed. The projo has been elevated above the table so that the fairing and shaping of the bottom planking can be done efficiently. It is still bolted to the table with 16 bolts. This arrangement preserves the orientation of the pattern to the drawing on the table. White fairing material is visible on the forward portion. Most of it will be sanded off.
Shot of the top view of the projo after sanding but before any fairing compound was used.
Shot from the base of the projo, the scale drawing that was used to set-up the station molds is visible on the table.
Another shot from the base of the projo. The white stuff is the fairing compound that fills in the space between adjacent planks. The projo was sanded smooth and fair prior to applying the fairing compound. It is nearly ready to have tooling gel coat spray on it. It will then be a shiny dark gray color. It will then be lowered back onto the table top drawing, waxed three times and sprayed with polyvinyl alcohol to ensure that it will release from the fiberglass and polyester resin that will be applied to make the mold for the "backside" of the projo. "The front side" will have the 14-1/4" x 20-1/4 raise flat area to which the plaque will be attached.
The plaques arrived today, 8 May 2006.
One will be sent on to Charlie Adamson in Lawton, for mounting on the soon to materialize, and long awaited, projo some time next week before the ceremony.
I opened the other one (the back-up). The picture does not due justice to how beautifully magnificent and detailed it really is.
Joe Gabig, owner of International Bronze, truly produced a masterpiece for our Battalion Memorial at Fort Sill on 20 May.
The back-up plan is for me simulate the green projo on 20 May, just in case it doesn't get finished in time... I hope the ceremony is short, the plaque is heavy!
Not to worry, events are tracking nicely since the switch back to epoxy based resins from the poly and vinyl esters.
More to come, while having fun, again!